Modified Atmospheric Packaging System And Method Of Use

ABSTRACT

A perishable food product packaging system in which a number of individual packages are initially unsealed and placed into the interior of a master package. The atmosphere within the interior of the master package is then modified, which modifies the atmosphere within the individual packages. The master package is then shipped to a retail location where the master package is opened, at which time the interior of the master package and the individual packages are exposed to conventional atmosphere. The individual packages are then sealed and prepared for retail sale, which typically will include weighing, pricing and labeling each individual package. The individual packages are then displayed in a “grab-and-go” refrigerated case, where a consumer can select one or more of the individual packages without having to be waited on by store personnel.

This application claims the benefit of and priority to U.S. provisional patent application Ser. No. 62/401,491 filed Sep. 29, 2016, the entire disclosure and contents of which are hereby incorporated by reference in their entirety.

This invention relates to a modified atmospheric packaging system for perishable food products, and more particularly to a system for packaging a number of individual packages of perishable food products in a common modified atmospheric package. The invention also relates to a method of making a modified atmospheric package containing a number of individual packages of perishable food products therein.

In supplying perishable food products, and particularly sliced perishable food products such as deli meats and cheeses or other items, it has been known in the past to prepare and till individual customer orders at the point of sale. This method typically involves an employee of a delicatessen or grocery store performing the steps of: slicing a desired number of slices from a bulk perishable food product; weighing those slices of the food product; printing a label to identify the food product, weight, price, etc.; packaging the sliced food product in a receptacle, such as a resealable or non-resealable plastic bag; and, applying the label to the package. However, performing these various steps is time consuming for both the delicatessen or grocery store employee and the customer. Furthermore, this method requires use of sharp machinery, such as electric meat slicers; the operation of which requires proper training to prevent injury.

Accordingly, in order to increase efficiency, some retailers have begun to pre-slice perishable food products such as popular deli meats and cheeses, prior to customers placing orders. Such pre-sliced food products are sliced from bulk perishable food products in-store; weighed; a corresponding label is printed; the food product slices are then packaged in a receptacle, such as a resealable plastic bag; and, the label is applied to the package. These packages are then often displayed in a refrigerated case, where a customer can select and personally retrieve the desired package of pre-sliced food product without engaging or requesting assistance from a delicatessen or grocery store employee. While this pre-sliced approach does limit the purchase time for customers, it does not reduce the workload for the delicatessen or grocery store employee. The time that the employee would have spent fulfilling orders for sliced food products has simply been reallocated to an earlier time period. Furthermore, this pre-sliced method does not reduce the employee's need to operate slicing equipment. Still further, this method of preparing and providing pre-sliced food products suffers from the additional disadvantage of the pre-sliced perishable food products potentially becoming spoiled, due to the relatively shorter shelf life of sliced products, in the event that they are not timely purchased by customers.

Accordingly, there is currently a need and desire to provide a method of packaging pre-sliced perishable food products, such as deli meats and cheeses, which will reduce employee preparation time and machine usage. There is also a need and desire to provide a method of packaging pre-sliced perishable food products that delays spoilage.

In one embodiment, the present invention contemplates a sealed or resealable package, preformed tray or pouch containing one or more unsealed food product receptacles therein, wherein a modified atmosphere, such as an inert gas, a vacuum, or a vacuum then an inert gas is disposed within the cavity of the sealed package, preformed tray or pouch.

In another embodiment, the present invention contemplates unsealed food product receptacles that may be sealable or non-sealable, and may or may not be configured to be sealed upon removal from the sealed package, preformed tray or pouch.

In another embodiment, the present invention contemplates a method of transporting sliced food products in a plurality of unsealed sealable or non-sealable receptacles disposed within a cavity of a sealed package, where the cavity of the sealed package comprises a modified atmosphere in the form of an inert gas.

Other aspects, features and advantages of the invention will become apparent to those skilled in the art from the following detailed description and accompanying drawings. It should be understood, however, that the detailed description and specific examples, while indicating certain embodiments of the present invention, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the present invention without departing from the spirit thereof, and invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

A clear conception of the advantages and features constituting the present invention, and that the construction and operation of typical mechanisms provided with the present invention, will become more readily apparent by referring to be exemplary, and therefore non-limiting, embodiments illustrated in the drawings accompanying and forming a part of this specification, wherein like reference numerals designate the same elements can be several views, and in which:

FIGS. 1 and 2 are representations of bulk perishable food products, such as deli meats, which are adapted to be packaged in accordance with the packaging system of the present invention;

FIG. 3 is a view illustrating a first step in the packaging system of the present invention, wherein a portion of the bulk perishable food product of FIG. 1 is separated, e.g. by slicing, and prepared for separate packaging, such as by positioning on a sheet of deli wrapping paper;

FIG. 4 is a view illustrating a number of the portions of the bulk perishable food product of FIG. 1 that have been separated, e.g. by slicing, and prepared for separate packaging, such as by positioning each portion on a sheet of deli wrapping paper;

FIG. 5 is view illustrating slicing the food product portions of FIG. 4 and separation of the food product portions from each other;

FIG. 6 is a view illustrating each individual food product portion, as in FIGS. 4 and 5, positioned within an unsealed receptacle, such as a sealable bag;

FIGS. 7 and 8 are views of the individual food product portion receptacles of FIG. 6 being placed within a sealable package, such as a sealable bag or pouch, that is sized and configured to receive a number of individual food product portion receptacles;

FIGS. 9 and 10 are views illustrating a number of the sealable packages as in FIGS. 7 and 8 being subjected to an atmosphere modification process for modifying the atmosphere within the sealable packages and therefore the atmosphere around the individual food product portion receptacles contained therein;

FIGS. 11-15 are views illustrating a single one of the sealable packages as in FIGS. 7-10, which is sealed and which contains a modified atmosphere within its interior, and within which a number of the individual food product portion receptacles of FIG. 6 are contained; and

FIGS. 16 and 17 are views illustrating a number of the sealed packages as in FIGS. 11-15 positioned within a container or carton for shipment.

In describing the embodiment of the invention which is illustrated in the drawings, to specific terminology will be resorted to for the sake of clarity. However, it is not intended that the invention be limited to be specific terms so selected and is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the words “connected,” “attached,” or terms similar thereto are often used. They are not limited to direct connection or attachment, but include connection or attachment to other elements where such connection or attachment is recognized as being equivalent by those skilled in the art.

DETAILED DESCRIPTION OF THE INVENTION

The various features and advantageous details of the subject matter disclosed herein are explained more fully with reference to the non-limiting embodiments described in detail in the following description.

Referring to FIGS. 1-17, a system for packaging a plurality of individual packages of perishable food products in a common modified atmospheric package is shown, along with a method of forming a common modified atmospheric package containing a plurality of individual packages of perishable food products therein. Referring initially to FIG. 1, a bulk perishable food product 10 is shown in a protective cover 12, prior to slicing. The bulk perishable food product 10 may be a meat product, such as turkey, beef, chicken, ham, etc., a sausage product, a cheese product, or any similar food product that be portioned or sliced from a bulk source prior to customer purchase. As used throughout the FIGS. 1-17, turkey will be shown as a non-limiting representative example; however, it should be understood that the present invention is not so limited. In addition, the following description will refer to portions of the food product 10 as being sliced from the bulk food product 10. It is understood, however, that the food product 10 may be portioned in any manner in addition to slicing, such as, for example, shredding, grinding, chopping, etc.

Turning now to FIG. 2, the protective cover 12 is removed from the bulk food product 10. The bulk food product 10 is then placed on a portioning device, such as, for example, at the inlet of a slicer 14. The slicer 14 may be a conventional automatic deli slicer, or a manual deli slicer that is configured to produce a single slice of meat, or other perishable food product, per pass of the traveling arm that retains the bulk food product 10. Alternatively, the slicer may be configured to produce multiple slices from the bulk food product 10, simultaneously. Either form of slicer 14 is considered well within the scope of the present invention. The bulk food product 10 is then fed through the slicer (not shown), and a plurality of slices 16 are output from the slicer 14.

As shown in FIG. 3, the plurality of slices 16 may or may not be placed on a sheet 18 of paper or plastic film, such as wax coated paper or conventional deli paper. The number of slices 16 included on a single sheet 18 may vary according to customer or manufacturer preference, and may be selected by net weight of the plurality of slices 16 or total number of the slices 16 within the plurality. By way of non-limiting example, ten (10) slices 16 are shown on the sheet 18 of paper in FIG. 3. As the plurality of slices 16 are output from the slicer 14, and placed on the sheet 18 of paper, the slices 16 and associated sheet 18 may or may not be placed together on the surface of a conveyer belt 20.

Turning now to FIGS. 4 and 5, the conveyer belt 20 transports the slices 16 and corresponding sheet 18 to a position 22, where one or more persons wrap the sheet 18 about the outer periphery of the slices 16, such that the slices are contained within the wrapped sheet 18. In this configuration, the slices 16 may be handled and processed while minimizing direct contact with the outer surface of the slices 16. Each of the portions of the plurality of slices 16, now wrapped in a sheet 18, are placed into an individual receptacle 24 by the individuals at position 22 (not shown in FIG. 5).

In one embodiment of the present invention, the receptacle 24 may be a plastic bag, such as a low density plastic bag, which may be printed or not printed, having a first wall 26 and second wall 28 that are joined along three edges, and a closure 30, which may be a resealable zipper-type closure or may be some other type of closure, disposed about an opening 32 that is located at a fourth edge of the receptacle 24. Alternatively the receptacle 24 may be provided without a closure, in this configuration, the walls 26, 28 define an interior or void space 34 within the receptacle 24 that is configured to receive the portion of the plurality of slices 16 wrapped in the sheet 18.

Turning now to FIG. 6, multiple receptacles 24 are shown, each containing a plurality of slices 16 wrapped in a sheet 18, located within their respective interiors 34. The closures 30 of the receptacles 24 are left at least partially open, i.e., unsealed. That is to say that the interior 34 of each receptacles 24 is at least partially exposed to atmosphere. Once filled with the sliced food product, as shown in FIG. 6, these open or partially open receptacles 24 are placed onto a conveyer 36 that transports the filled receptacles 24 to a position 38.

While the above description relates to transport of the slices and receptacles via conveyor, it is understood that any type of transport as desired may be employed such as, but not limited to, manual hand conveyance and placement, placing the receptacles into a transport container for further transport, etc.

Turning now to FIGS. 7 and 8, one or more persons at position 38 receive the filled receptacles 24 from the end of the conveyer 36. The receptacles 24 are then placed into a preformed recessed well 40 formed in a bottom web 42 of material. As will be described in further detail below, the bottom web 42 is configured to be sealed to a top web 44 about the outer edges of the well 40 to form a sealed package 46. In one embodiment of the present invention, the material that forms the bottom web 42 and top web 44 may be a clear single or multilayer film, formed of plastic or any other satisfactory material in a as is known, which can be molded and/or melted with exposure to heat, including but not limited to low density polyethylene, polyvinyl chloride, ethylene-vinyl acetate, or oriented polypropylene. Representatively, the bottom web 42 may be supplied from a roll of material in a packaging machine of the type that vacuum forms the bottom web 42 to define the wells 40, and which applies the top web 44 over the wells 40 of the bottom web 42 once the cavity is filled, in a manner as is known.

Still referring to FIGS. 7 and 8, at position 38 multiple filled receptacles 24 may be placed into each of the preformed recessed wells 40. In one embodiment of the present invention, shown in FIGS. 9-17, multiple filled receptacles 24 are placed into each of the preformed recessed wells 40. It is understood that any number of filled receptacles 24 received within the wells 40 are considered well within the scope of the present invention.

Turning now to FIGS. 9 through 11, multiple filled receptacles 24 are shown disposed into each of the various preformed recessed wells 40, which are formed in the bottom web 42. The wells 40 of the bottom web 42 are defined by a first wall 48, a second wall 50, a third wall 52 and a fourth wall 54. Each of the walls 48, 50, 52, 54 extends from a bottom surface 56, to an upper edge 58, where the upper edge 58 extends about the well 40 and borders a sealing surface 60 that is configured to face and engage the top web 44 when forming the sealed package 46, as will be described in further detail below. Each of the walls 48, 50, 52, 54 may have a height, which defines the depth of the well 40, sufficient to receive the multiple filled receptacles 24 within the well 40, while the receptacles 24 do not extend upwardly above the upper edge 58 of the well 40. That is to say that in one embodiment of the present invention, the receptacles 24 are located in the well 40, below the upper edge 58. In this configuration, the receptacles 24 will not interfere with the sealing of the bottom web 42 and top web 44 in the forming of the sealed packages 46. Furthermore, as shown in. FIGS. 9 and 10, the closures 30 of the receptacles 24, are fully or partially open, i.e., unsealed, as to at least partially expose the interior 34 of each receptacle 24 to atmosphere.

Once the filled receptacles 24 have been properly placed within the wells 40, as shown in FIGS. 9 through 11, the bottom web 42 is advanced to a modified atmospheric packaging sealer (not shown). In order to prolong shelf life and postpone spoilage, in the process of forming the sealed packages 46, or after the packages 46 are formed but before sealing, atmospheric air is removed from the interior portion of the well 40, and also from the interiors 34 within the receptacles 24, as a result of the closures 30 of the receptacles 24 being at least partially open, i.e., unsealed. Furthermore, an inert gas is injected into the well 40 and interiors 34 of the filled receptacles 24, either with or without vacuumization of the package 46 via a process known as gas flush with or without vacuum packaging. In one embodiment of the present invention, the inert gas may be selected from one or more of N₂, CO, CO₂, and/or a mixture thereof. In other instances an oxygen scavenging packet may also be placed into each sealed package 46 along with the filed receptacles 24 that are being packaged. Once the sealed packages 46 have been formed, the individual sealed packages 46 are cut away from the integrated webs 44, 46.

Each package 46 may be formed in a manner as is known by forming a cavity in a the bottom web 42, placing products into the cavity, and then scaling the cavity using the top web 44, in what is commonly known as a form, fill and seal process. Alternatively, the cavity may be defined by a preformed tray, which is then sealed using an overlying web, or a single web may be folded over onto itself, which forms a pouch. The seal that surrounds the cavity of the package forms a microbial barrier that prohibits contamination of the perishable food products contained therein. The package or pouch also provides a protective enclosure for other packaged items. Commonly, the package 46 includes a resealable closure, such as a zipper-type closure or other means such as resealable adhesive film, to close the cavity for product storage after the seal has initially been broken.

Turning now to FIGS. 1-17, various views of the sealed packages 46 are shown. In these packages 46, the outer edge 62 of the top web 46 has been sealed to the sealing surface 60 of the bottom web 44, located about the upper edges 58 of the well 40. As such, the package 46 defines a sealed cavity 62 for retaining the plurality of sliced perishable food product filled receptacles 24, therein. The seal line 64 extends entirely around the sealed package 46, as to prevent atmosphere from entering the sealed cavity 62.

Turning now to FIGS. 16 and 17, multiple sealed packages 46 are shown placed into a shipping container 66, for transportation to a retail establishment such as a grocery store or delicatessen. Once the shipping container 66 arrives at the retail establishment, the desired amount of sealed packages may be opened by peeling the top web 46 from the bottom web 44, i.e., breaking the seal line 64 and extracting the filled receptacles 24 therefrom. The closure 30 disposed about the opening 32 of each receptacle 24 may then be closed. The retail establishment may then weigh the packaged product and apply a custom label to the outer surface of the receptacle as to indicate content, weight, price, best-use by date, etc. prior to displaying the filed receptacles for customer purchase. In a typical application, the retailer will place some or all of the receptacles 24 into a refrigerated case where other similar products are displayed, such that consumers can select the desired product by type and weight. The consumer can then proceed directly to checkout or continue shopping, without having to wait for deli service. As can be appreciated, this saves the retailer considerable time and expense in both manpower and equipment usage, and enables the retailer to manage inventory and control stock so as to minimize spoilage.

It can thus be appreciated that the present invention contemplates a number of individual packages that are initially unsealed and placed into the interior of what may be referred to as a master package or multi-pack. The atmosphere within the interior of the multi-pack is then modified, such as via gas flushing with or without vacuum packaging. The multi-pack, either on its own or more typically with many additional multi-packs, is then packaged into a container or carton for shipment to a distributor or to a retail location. These steps will typically occur at a production facility, which may be located where the food product is produced or may be at some other location. Once the multi-pack arrives at its final retail destination, which typically will be geographically removed from the production facility, the multi-pack is opened, at which time the interior of the multi-pack and the individual packages are exposed to conventional atmosphere. At the retail location and after the multi-pack is opened, the individual packages are sealed and then prepared for retail sale, which typically will include weighing, pricing and labeling each individual package. The individual packages are then displayed in what is commonly referred to as a “grab-and-go” refrigerated case, where a consumer can select one or more of the individual packages without having to be waited on by store personnel.

It should be understood that the invention is not limited in its application to the details of construction and arrangements of the components set forth herein. The invention is capable of other embodiments and of being practiced or carried out in various ways. Variations and modifications of the foregoing are within the scope of the present invention. It is also understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text and/or drawings. All of these different combinations constitute various alternative aspects of the present invention. The embodiments described herein explain the best modes known for practicing the invention and will enable others skilled in the art to utilize the invention. 

We claim:
 1. A sealed package, comprising: a first packaging component defining an internal cavity; an air tight seal about the internal cavity of the first packaging component; an inert gas disposed within the internal cavity of the first packaging component; a plurality of unsealed, sealable or unsealable receptacles disposed within the internal cavity of the first packaging component; and the one or more sealable or unsealable receptacles having an interior within which a food product is contained; wherein the interior of each receptacle is in fluid communication with the internal cavity of the first packaging component.
 2. The sealed package of claim 1, wherein the first packaging component comprises a package formed of a pair of sealed webs of packaging material.
 3. The sealed package of claim 1, wherein the first packaging component comprises a pouch formed of a web of packaging.
 4. The sealed package of claim 1, wherein the first packaging component comprises a preformed tray and wherein a web of packaging material is sealed to the preformed tray form the air tight seal about the internal cavity of the preformed tray.
 5. The sealed package of claim 1, wherein the plurality of receptacles disposed within the internal cavity of the first packaging component comprises a plurality of bags each having a reclosable seal.
 6. A method of packaging perishable food products, comprising the steps of: preparing a plurality of portions of a perishable food product; placing a number of portions of the perishable food product into an interior defined by each of a plurality of individual unsealed sealable or unsealable receptacles; placing the plurality of the unsealed sealable or unsealable receptacles into a cavity of a package, wherein the interior of each receptacle is in fluid communication with the cavity of the package; and modifying the atmosphere within the cavity of the package and sealing the cavity to form a package in which the modified atmosphere is maintained within the cavity and the interior of each receptacle is exposed to the modified atmosphere.
 7. The method of claim 6, wherein the method is carried out in a first location and the package is shipped to a second location remote from the first location, wherein at the second location the package is opened and the individual receptacles are sealed or not sealed, weighed, labeled and displayed for purchase by consumers.
 8. The method of claim 6, wherein the step of placing each portion of the perishable food product into the interior defined by each of a plurality of individual receptacles comprises placing each portion of the perishable food product into the interior of a reclosable bag-type receptacle.
 9. The method of claim 6, wherein the step of modifying the atmosphere within the cavity of the package is carried out by gas flushing the interior of the package.
 10. The method of claim 9, wherein the step of modifying the atmosphere within the cavity of the package includes evacuating the interior of the package.
 11. A packaging system for perishable food products, comprising: a plurality of receptacles, each of which defines an interior within which a portion of a perishable food product is contained; a package defining an internal cavity, wherein the plurality of receptacles are contained within the internal cavity and wherein each receptacle is configured such that its interior is open to the internal cavity of the package when the receptacle is contained within the internal cavity of the package; and a modified atmosphere contained within the internal cavity of the package and a seal that closes the internal cavity and contains the modified atmosphere therewithin, wherein the seal that closed the internal cavity of the package maintains the modified atmosphere within the internal cavity of the package and within the interior of each of the plurality of receptacles.
 12. The packaging system of claim 11, wherein each receptacle includes a closure, wherein the closures of the receptacles are at least partially opened when the receptacles are positioned within the internal cavity of the package.
 13. The packaging system of claim 12, wherein the modified atmosphere contained within the internal cavity of the package comprises an inert gas.
 14. The packaging system of claim 13, wherein the modified atmosphere contained within the internal cavity of the package comprises a vacuum in addition to the inert gas.
 15. A packaging system of claim 11, further comprising a shipping container within which a plurality of the packages are contained, wherein the shipping container is adapted to be filled at a facility at a first location and shipped to a retail establishment at a second location remote from the first location.
 16. The packaging system of claim 15, wherein at the retail establishment, the package is opened, the receptacles are withdrawn from the package and sealed, and the receptacles are then displayed for retail sale. 